TemperZone EcoULTRA OPA 2100RKTM-P Maintenance and service guide

OPA 1400/2100 RKTMF-P (Eco Ultra) c/w UC8
Air Cooled Packaged Units - Reverse Cycle - R410A
Installation & Maintenance
CONTENTS Page
1. General ................................................................1
2. Installation............................................................1
3. Refrigeration System......................................... 1
4. Wiring.................................................................. 2
5. Start-Up Procedure........................................... 4
6. Operation............................................................ 5
7. Economiser..........................................................7
8. Maintenance....................................................... 8
9. Troubleshooting.................................................. 8
10. Warranty............................................................ 8
Appendix I: Controls Set-up IP Address..............9
Appendix II: Master Controller - System Info......10
Appendix III : UC8 Protection Functions.............11
Appendix IV: Air Handling Performance.............13
1. GENERAL
Temperzone OPA Outdoor Air Cooled Packaged units.
Follow these instructions to ensure the optimum
performance, reliability and durability.
Units must be installed in accordance with all national and
regional regulations and bylaws. National Health and Safety
regulations must be followed to avoid personal injuries.
The appropriate local permits must be acquired and
adhered to.
Local regulations on maximum boundary noise need to
be considered when positioning the unit.
2. INSTALLATION
2.1 Clearances & Service Access
Refer to Specication Sheet supplied for minimum
clearances. If multiple units are to be placed side-by-
side then allow at least 2m between coil faces.
Filter slides are tted within the unit. Access to the lter
access door should be considered when designing
return and supply air ductwork. Access to the lters can
also be achieved by removing the return air access door.
2.2 Mounting
The unit should be fastened to a rm at horizontal
base using the holes supplied in the mounting
channels. When the unit is being installed on a roof it is
recommended that the unit is installed on a substantial
structure with vibration isolating pads or mounts. If
placed on the ground or concrete pad, use rubber pads
or mounts to give 20mm min. ground clearance.
Flexible duct connections are recommended between
the supply and return ducts and the unit.
Unit is shipped with wooden blocks installed under the
compressors. Ensure these blocks are removed from
the compressor feet prior to starting the unit
(not required for operation).
2.3 Condensate Drains
The condensate drains should be ‘U’ trapped outside
the unit. The traps should have a vertical height of at
least 100 mm. The drain lines should have a slope of at
least 1 in 50 and must not be piped to a level above the
unit drain pipe.
OPEN
DRAIN
MINIMUM
SLOPE
20 mm PER m
(1 IN 50)
100 mm
MINIMUM
200 mm
APPROX.
'U' TRAP
100 mm
APPROX.
VENT PIPE
FOR LONG
CONDENSATE
DRAIN RUNS
003-000-134 11/21
3. REFRIGERATION SYSTEM
3.1 General
The OPA 1400/2100 has four independent refrigeration
systems and four inverter compressors to provide the
exibility and economy of four stage operation, i.e.
utilising one to four systems as conditions vary, plus
the advantage of staggered starting, all stages being
variable for improved control and system efciency.
Each refrigeration system has been charged with
HFC-410A (R410A) refrigerant; refer Specications
document for amount.
3.2 Compressors
The compressors are inverter scroll type. The
compressor lubricant is polyolester oil (POE). Note, this
oil absorbs moisture quickly if exposed to open air.
GENERAL
INSTALLATIONREFRIG. SYSTEM

- 2 -
WIRING
4. WIRING
4.1 Electrical Requirements
Electrical work must be done by a qualied electrician.
DANGER! LIVE ELECTRICAL CONNECTIONS. ISOLATE MAINS
POWER BEFORE WORKING ON UNIT. ONLY QUALIFIED PERSONS
WHO ARE COMPETENTLY TRAINED SHOULD PERFORM SERVICE
AND MAINTENANCE TASKS.
The unit must be wired directly from a distribution board
using an appropriately sized circuit breaker based on
AS/NZS 3000. The termination point for the mains cable
in the unit is at the isolator switch.
Note: DO NOT USE REWIRABLE FUSES.
4.2 Controls Wiring
Before wiring, the method of control should be
established from the following list. Follow specic
instructions in the following sections. Section 4.3 is
important to all sections.
Control method Section
Sensors and Inputs 4.3
BMS – BACnet Interface 4.4
BMS – Modbus Interface 4.5
BMS – Low Level Controls 4.7
Standalone 4.8
4.3 Sensors & Inputs
See table below for sensors and inputs required for each
control method.
Carel c.pCO
connections
Factory
Fitted
BMS
Bacnet/
Modbus
BMS -Low
Level
Controller
Stand
alone
Sensor Pin Signal
Room Temp. U1 0-10VDC Note 1 Note 3 × √
Room RH% U2 0-10VDC Note 1 Note 3 × √
ID Fan Speed
Req
U3 0-10VDC × Note 2
RA Temp. U4 0-10VDC √ √ √ √
RA RH% U5 0-10VDC √Note 4
SA Temp. U6 0-10VDC √ √ √ √
SA RH% U7 0-10VDC √ √ √ √
The following inputs relate only when using external low level control:
Capacity
Input
U8 0-10VDC × × √×
Enable ID4 24VAC × × √×
Heat ID5 24VAC × × √×
Occupancy ID6 24VAC × × √×
Dehum ID7 24VAC × × √×
Fault NO7 Relay × × √×
Notes:
1. Factorysuppliedloose,tasrequiredincontrolled
space.
2.Optionallyprovide0-10VDCcontrolofindoorfan
speed,willbeoverriddenifwrittentoBACnetor
Modbusindoorfanspeedregister.Canalsobeset
usingaCarelpGD.
3.RoomtemperatureandRH%canbewrittenvia
BACnetorModbusandwilltakepriorityoversensor
reading,inthiscasesensorsarenotrequiredtobe
tted.
4.RAsensorsonlyrequiredforEconomiseroption.IfRA
tobeusedtocontrolthespacethenwireRAsensors
intotheRoomtemperatureandRoomRH%inputs.
4.5 BMS – BACnet Interface
1. Install ethernet cat 5 STP shielded cable between
the port shown in the below diagram of the Carel
c.pCO controller and the network switch of the
BMS. The default IP address of the controller is
192.168.1.10; refer Controls Setup (p.9) for details on
how to change.
2. Temperature and humidity sensors can be
connected directly to the Carel c.pCO controller (see
specication sheet for wiring diagram). Alternately
the space temperature and humidity can be written
by the BMS to BACnet objects which will take
priority over any sensors that are connected.
SingleunittoBMS:
Multipleunitsusinganetworkswitch:

- 3 -
4.6 BMS – Modbus Connection
Connect to supplied terminals in electrical box, see
technical document for wiring detail, sheet 2 sheet
reference DO, reproduced below.
Figure 1: RS485 terminal block in electrical box
Figure 2: Carel recommendations for shield grounding
4.7 BMS – Low Level
Provide the controller with 24VAC input signals from
external controller.
• Enable – turn operation of unit on and off.
• Heat – Room temperature is below set point
(heating required).
• Capacity – 0-10VDC signal based on capacity
required.
• Dehum – On, prioritize moisture removal.
Comfort
Mode
Heat Dehum Comfort
Zone
Standard
Cooling
High
Latent
Enable 24V 24V 24V 24V 24V
Heat 24V 24V or 0V 24V or 0V 0V 0V
Capacity 0-10V DC 0VDC 0-10V DC 0-10V DC 0V DC
Dehum 24V 24V 0V 0V 24V
An output for unit fault is provided (NO7).
4.8 Stand Alone
Option 1:
1. Install optional Carel pGD remote display (Item no.
201-000-379) inside building, connection to c.pCO
J10 port. Cable RJ-45.
2. Connect Room temperature and humidity sensor
directly to Carel c.pCO controller. See Specication
sheet for wiring schematic/sheet 2 for wiring details
of Room temperature input) and Room RH%.
Option 2:
In absence of a Carel remote pGD the unit can be
controlled using the onboard master controller with its
included digital display.
Low Level
Where a third party control or thermostat outputs
switched 24V signals and a capaciy signal.
4.8 Economiser Wiring
See Specications document for wiring schematic/
sheet 1, lower left corner.
WIRING
BMS
RS GND
RSA
RSB
18
ENG
c.pCO sistema +0300057EN rel. 1.1 - 13.04.2015
J3 Disp
+Vterm
LH
J4 FBus J5 CAN J3 Disp J4 FBus J6 BMS
+Vterm
J3 Disp J4 FBus J6 BMS
+Vterm
G
G0
G
G0
G
G0
24 Vac
LN
230 Vac
24 Vac
LN
J25 BMS2 J26 FBus2
J11 pLAN
c.pCO
G
G0
J25 BMS2 J26 FBus2
J11 pLAN
c.pCO
G
G0
J25 BMS2J26 FBus2
J11 pLAN
c.pCO
G
G0
Fig. 4.e
The procedure for earthing the shield is described in the corresponding
paragraph.
Case 2: multiple boards connected to a Master/Slave network powered
by diff erent transformers (with G0 not earthed); this is a typical application
of multiple boards inside diff erent electrical panels. If the network is more
than 100 m long, the 120 Ω, ¼ W terminating resistor is required.
J3 Disp
+Vterm
LH
J4 FBus J5 CAN J3 Disp J4 FBus J6 BMS
+Vterm
J3 Disp J4 FBus J6 BMS
+Vterm
G
G0
G
G0
G
G0
230 Vac
24 Vac
LN
230 Vac
24 Vac
LN
230 Vac
24 Vac
LN
R = 120 Ω R = 120 Ω
J25 BMS2 J26 FBus2
J11 pLAN
c.pCO
G
G0
J25 BMS2 J26 FBus2
J11 pLAN
c.pCO
G
G0
J25 BMS2 J26 FBus2
J11 pLAN
c.pCO
G
G0
230 Vac
24 Vac
LN
230 Vac
24 Vac
LN
230 Vac
24 Vac
LN
R = 120 Ω R = 120 Ω
Fig. 4.f
Important: the earth connection (if any) should be made only on
one point of the earth line (same earthing terminal for all controllers).
The procedure for earthing the shield is described in the corresponding
paragraph.
Optically-isolated serial port
This is the case of serial ONE - BMS1, serial TWO - Fieldbus 1 and the built-
in ports serials THREE and FOUR on optically-isolated models. Regardless
of the type of power supply or earthing, use a 3-wire shielded cable
connected as shown in the fi gure. If the network is more than 100 m
long, the terminating resistor is required.
J25 BMS2 J26 FBus2
J11 pLAN
c.pCO
G
G0
J25 BMS2 J26 FBus2
J11 pLAN
c.pCO
G
G0
J25 BMS2 J26 FBus2
J11 pLAN
c.pCO
G
G0
R = 120 Ω R = 120 Ω
Power
supply
Fig. 4.g
The procedure for earthing the shield is described in the corresponding
paragraph.
Procedure for earthing the shield
The shield of the serial cable is earthed diff erently according to the
length, as shown in the fi gure (where A=FBus terminal, B=BMS terminal).
Case 1: distance between controllers less than 0.3 m: earth only one end
of the cable.
L < 300 mm
L < 300 mm
AB B
Fig. 4.h
Case 2: distance between controllers greater than 0.3 m: two possibilities.
- earth one end with a bridge between the shields
L >300 mm
L > 300 mm
AB B
Fig. 4.i
- earth both ends of the cable (no bridge between shields).
L >300 mm
L > 300 mm
AB B
Fig. 4.j

- 4 -
START UP PROCEDURE
5. START-UP PROCEDURE
5.1 Before starting the compressors
1. Before working on the unit isolate mains power.
2. Remove the shipping blocks from beneath each
compressor. Check that each compressor is
securely mounted.
3. Check oil level as per label attached to each
compressor.
4. Check the mains power and controls wiring are
correct.
5. Check tightness of all electrical connections.
6. Check the air lters have been correctly installed.
7. Check that all indoor fan motors can freely rotate.
8. Check the supply voltage between each phase and
neutral.
9. Check air diffusers and ductwork are open.
10. Apply mains power to the unit by closing the mains
isolating switch.
11. Before starting the compressors a four hour delay
period is required to allow the crankcase heaters to
drive any liquid refrigerant out of the compressor oil.
Mains power must be switched on during this four
hour delay period.
5.2 Master Controller Display
Button Function
Alarm System Alarm indication and Reset
Esc Return to previous page or Exit menu
Home page display:
Main Menu:
A detailed Master Controller User Guide is supplied with
the unit, and available at www.temperzone.biz; model
search ‘OPA 2100’.
5.3 Commissioning
After the four hour delay period has expired (see step
10 in section 5.1) complete the following procedure. You
can use the Commissioning Sheet (supplied with the
unit) to help you.
1. From the initial screen of the Master Controller press
program button to bring up the Main menu.
2. Scroll down and select ‘B settings’.
3. Scroll down and select ‘Commission’.
4. The rst page shows Airow setup. Enter the
required Air ow in l/s. (refer Note below)
5. Measure air ows from duct work to verify air ows.
6. Scroll down to the next page, ‘Commission
Systems’.
7. On this page is a list of all systems, each system
can be turned on and the capacity set.
8. Turn each system on in isolation. Leave the capacity
at the default 75%. Allow to run checking for any
unusual noises or vibrations.
9. Measure the current draw on each phase to the
compressor motor and to each fan motor. Check the
readings against the specied values in the wiring
diagram or Specication sheet.
10. Check each refrigeration system’s information, from
the Main menu select ‘Information’, then ‘UC8’ (refer
Appendix I for more detail). Also check Information/
Power usage.
11. Return to Main menu/Settings/Commission to repeat
step 7 to 9 with each system individually.
12. Run all systems simultaneously as a nal check.
13. Touch up any outdoor unit paintwork damage to
prevent corrosion.
Note:
Setting the indoor fan speed too low can bring risk of
frost forming on the indoor coil with potential nuisance
frost protection trips on cooling, possibly even unit lock-
out, and/or HP trips on heating.
Setting the indoor fan speed too high can bring a risk of
blowing moisture off the ns of the indoor coil and into
the supply air duct. Water could then start leaking from
the supply air grilles and corrosion of ducting may occur.
Setting the indoor fan speed too high can also bring a
risk of ‘over-condensing’ (when the unit is heating) which
in turn could cause the unit to perform more outdoor coil
de-ice cycles than necessary.
Outdoor fans do not necessarily start rotating
immediately after the compressor is started. The fans
may run-on for a short period after the compressor
stops.

- 5 -
6. OPERATION
6.1 BMS – BACnet
Congure the IP address as required, see Appendix for details.
Once connected to the BMS server, to start the unit via BACnet if the room temperature and RH% sensors are connected
directly to the controller and the indoor fan speed has been set using the PGD then all that needs to be done is to write to
the below BACnet objects.
Type Object
Instance
Object Name Read/Write Units Default Range Description
BinaryValue 1BMS_OnOff RW Bool 0 0 to 1 Enable Unit to run
AnalogValue 30 BMS_RoomT_Cool_
SP
RW °C 22 5 to 35 Cooling SP, must be > heat SP
AnalogValue 31 BMS_RoomT_ Heat_
SP
RW °C 20 5 to 35 Heat SP, must be < cool SP
If the Room temperature and RH% are measured by the BMS then the below objects also need to be written.
Type Object
Instance
Object Name Read/Write Units Default Range Description
AnalogValue 36 BMS_RoomT RW °C -5-35 Room temperature written by
BMS
AnalogValue 37 BMS_RoomRH RW RH% -0-100 Room RH% written by BMS.
BinaryValue 4BMS_RoomT_RH_
ORide
RW Bool 0Bool Use BACnet Room temp and
RH (BMS_RoomT and BMS_
Room_RH) for control
To adjust the air ow via BACnet the following object need to be written.
Type Object
Instance
Object Name Read/Write Units Default Range Description
AnalogValue 44 BMS_
AirFlowSetpoint
RW l/s 10000 0-13750 Air ow l/s setpoint
6.2 BMS Modbus
For information regarding using Modbus commands, please ask temperzone.
6.3 Stand Alone
Adjusting the set points:
1. Press Program button .to bring up the Main Menu
2. Select B.Settings, Login information will then be
needed. Default password is 0001, this can be
changed by user.
3. Select Setpoint
OPERATION

- 6 -
OPERATION
4. Press enter then use Up/Down keys to adjust the
value or press enter key to move to the next value.
5. Scroll down to the next page. Adjust the RoomRH
Setpoint. The setting for the high latent point can
also be adjusted, when the room conditions are
above this level the capacity will increase to bring
the space under control faster. The value needs to
be larger than the RoomRH set point.
6. Scroll to the next page. If the reheat coils are
tted, then the supply air temperature when in
dehumidication mode (temperature in dead band
and RH above room RH set point) can be adjusted.
The setting is an offset from the current room cooling
set point.
7. Scroll to the next page. If the reheat coils are tted
then a minimum supply air can be set. There are two
control modes available, the rst allows setting the
supply air to a xed value, the second mode is an
auto function that offsets the supply air above the
current room dew point, the aim being to prevent
moisture formation on duct work.
8. Scroll down to the next page. Here the selection
can be changed from the default Standard to High
Sensible, High Latent or Custom setting. Each of
these presets changes the offset from the current set
dew point (calculated from the set room temperature
and RH%) to determine the target evaporating
temperature. The condensing temperature for
heating is a xed value. The set point values shown
on this page are based on the current room set
points along with the comfort.
9. Scroll down to the next page. If the Economizer
dampers are tted, the minimum and maximum
closed and open positions can be set. (nb OA =
Outdoor Air, ie fresh air)
10. Scroll down to the next page. If the Spill Air dampers
are tted, the minimum and maximum closed and
open positions can be set.
11. Scroll down to the next page. A pressure sensor is
factory tted to the indoor fans allowing the air ow
to be automatically controlled. Set the ow in l/s.
The settings for the PI control are also on this page,
leave as factory set.

- 7 -
7. ECONOMISER
7.1 Economiser Option
The Economiser package that is factory tted consists of two opposed blade dampers, one for the fresh air and the other
for the return air. They come complete with individual damper motors controllable from a 0–10V dc or 24V ac signal. The
package also includes a weatherhood assembly that is usually supplied as a separate item for tting on site.
If the outdoor enthalpy and temperature is below that of the return air, the fresh air damper can be opened and the return
air damper closed to provide the rst stage of cooling.
It is important that the installation instructions for the tting of the weatherhood are followed otherwise it is possible some
water ingress from rain could occur.
The fresh air damper’s adjustable stop can be set such that it does not close 100%. Many installations may require
a minimum fresh air introduction of 10–15% (refer local Building Code regulations) and the stop may be set on site to
facilitate this. Ensure the air ow is equal between full return air and full Economiser by adjusting the damper stops on
both Return and Fresh air dampers.
As previously mentioned a 0–10V dc control signal is required to drive the dampers open and closed. This is supplied by
the Master Controller (c.PCO), which opens the economiser based on enthalpy measurements of the fresh air and return air.
Air Quality (CO2) sensors can be used to proportionally control the fresh and return air dampers (via the BMS control
system).
12. On the next screen you can set whether the indoor
fan runs when the room conditions have been
achieved.
13. The following screen allows the adjustment of the set
points when an unoccupied request is received.
To power on the unit from the controller follow the below instructions:
1. From the main screen, use the up and down keys to
select the ON/Off symbol as shown in the screen in
the lower righthand corner. Press enter.
2. At the next screen use the Up/Down Key to turn the
unit On then press enter to conrm.
OPERATIONECONOMISER

- 8 -
TROUBLESHOOTING
9. TROUBLESHOOTING
9.1 Roomtemperaturevariessignicantlyfromits
setting
• Unit may have been incorrectly sized for the building.
• Drafts from wrongly placed supply air diffusers or
from the back of the wall plaque could be affecting the
temperature sensor built into the wall plaque.
• Poor air circulation in the room can cause incorrect
temperature readings.
9.2 Air conditioner does not seem to deliver the heating
when most needed
• Heating capacity at design conditions may be
incorrect. As the outside temperature falls, heat losses
through the walls, oor and ceiling increase.
• Check the unit’s brochure for information on the
minimum/ maximum operating temperatures.
9.3 When heating, units have de-icing cycles built in to
remove ice on the outdoor coil.
• This usually means reversing the cycle for a few
minutes during which time there is no heating and in
fact a little cooling can occur.
9.4 In a new building, why does it take some days
before the air conditioning heat pump unit seems to
work properly
• Many new buildings, especially a commercial buildings,
have a large amount of concrete and other structural
materials that are generally cold and full of moisture.
This is most evident in the winter when trying to heat
the building from scratch.
9.5 Unit is leaking water
• Check the drain trap/vent/slope.
• Water carry-over: Reduce the maximum fan speed.
9.6 Air conditioner runs excessively – the temperature
remains too hot in summer or too cold in winter.
• Windows or doors may be opened to non conditioned
areas.
• Keep doors to unconditioned areas closed.
• Leaves, papers or other items blocking air ow over the
outdoor unit coil.
• Location of wall controller or remote temperature
sensor is incorrect.
• Check for leaks in supply or return air ductwork.
9.7 Unit displays an error code:
• Refer to UC8 Controller label on the unit for
operation & fault diagnostics information or visit
www.temperzone.biz; model search ‘UC8 Controller’.
• Press the Alarm button on the pGD to list the most
recent faults. Refer OPA 2100 Controller Manual for an
explanation.
MAINTENANCE
8. MAINTENANCE
WARNING HAZARDOUS VOLTAGE. ENSURE ALL POWER SUPPLIES ARE
ISOLATED BEFORE PERFORMING MAINTENANCE. FAILURE TO ISOLATE
POWER CAN LEAD TO SERIOUS INJURY.
8.1 Monthly
1. Check air lters and vacuum or wash clean as
necessary.
2. Check condensate drain for free drainage.
3. Check compressor compartment for oil stains
indicating refrigerant leaks.
4. Check system operating pressures via the Carel
c.PCO controller (refer Appendix I).
8.2 Every Three Months
1. Check operation of Economiser dampers.
2 Check for obstruction of Economiser dampers.
8.3 Six Monthly
1. Check the tightness of electrical connections.
2. Check for signs of corrosion on electrical connections
in high salt atmospheres; replace where necessary.
3. Check the tightness of all fans, motor mountings
4. Check system operating pressures via the Carel
c.PCO controller (refer Appendix I).
5. Check and/or replace indoor air lters
6. Check condensate drain for free drainage.
8.3 Yearly
1. Check all refrigerant piping for chang and vibration.
2. Check air supply at all diffusers
3. Check for excessive noise and vibration and correct
as necessary.
4. Check for insulation and duct damage and repair
as necessary.
5. Check system operating pressures via the Carel
c.PCO controller (refer Appendix I).
6. Remove lint and dust accumulation from outdoor
coil ns with soft brush or low pressure water spray.
In corrosive environments, the checking and cleaning
frequency should be increased.
7. Touch up any paintwork damage to prevent corrosion.
WARRANTY
10. WARRANTY
Please refer to the separate warranty document supplied with the unit, or visit www.temperzone.biz for details.
Australia: New Zealand:
[e-mail] [e-mail]
[e-mail] Telephone: 0800 TZWARRANTY (899 2777)
Telephone: [phone]

- 9 -
APPENDIX I
CONTROLS SET-UP : IP ADDRESS
The default IP address of the controller is ‘192.168.1.10’. To change follow the below instructions.
1. Press Alarm and Enter together for 3 seconds to
access the system menu
2. Scroll to ‘TCP/IP settings’ and press Enter button
3. Select Settings:
DHCP: OFF
Enter an address in the same subnet set on the PC,
for example:
IP: 192.16 8.0.1
MASK: 255.255.255.
Select Update conguration --> Yes
APPENDIX I – CONTROL SET-UP : IP ADDRESS

- 10 -
APPENDIX II
MASTER CONTROLLER : SYSTEM INFORMATION
1. Press Program button .to bring up the Main Menu
Select ‘A. Information’.
2. Select ‘UC8’.
There are four separate UC8 controllers in an
OPA 2100 – one per refrigeration system.
3. UC8 Info. screens. These show the UC8 controller
variables such as suction superheat, expansion
valve position, etc. Refer table below for key to
abbreviations:
Abbrev.. Description
OAT Ambient Temp. °C
DeICe De-ice sensor temp. °C
SLT Suction line temp. °C
EvapT Evaporation temp. °C
DLT Discharge line temp. °C
CondT Condenser temp. °C
SSH Suction superheat K
DSH Discharge superheat K
ODF Outdoor fan speed
IDF Indoor fan speed
HP Discharge pressure kPa
LP Suction pressure kPa
EXV1 Expansion valve A %
EXV2 Expansion valve B %
OCT Outdoor Coil Temp. °C
ICT Indoor Coil Temp. °C
4. Scroll down to see UC8 systems 2 to 4.
5. Press Program button to return to the Main Menu
APPENDIX II – MASTER CONTROLLER SYSTEM INFORMATION